Rectangular Lithium-Ion Battery Cell With Gasket Core Retention
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current lithium ion battery cells for electric and hybrid vehicles are deficient in power output, reliability, and safety, with issues such as short-circuits and explosions due to unreliable electrochemical constructions and interconnections.
Innovation Solution
An electrochemical storage cell design featuring a coiled core with a rectangular shell and gaskets to securely hold the core, along with a frangible connector system that breaks under excessive forces, and overcurrent protection mechanisms to prevent electrical disconnection and ensure safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple individual battery cells are interconnected to increase power output, then the combined power output provides necessary driving power, but the interconnections become unreliable and safety issues arise
Solution Approach 1:
The battery system is divided into multiple individual battery cells that can be interconnected in series or parallel configurations. Each cell is a self-contained unit with its own housing, terminals, and protective features, allowing the system to achieve high power output while maintaining reliability through modular design.
Solution Approach 2:
A connector assembly serves as an intermediary component between battery cells, providing reliable electrical interconnection. The connector includes conductive elements, insulating housing, and safety features that ensure stable connections while protecting against short circuits and environmental damage.
2Ease of manufacture
If conventional battery cell constructions are used, then manufacturing is simpler, but short-circuits and explosions occur due to unreliable electrochemical constructions
Solution Approach 1:
The battery cell housing includes pre-designed safety features such as pressure relief vents, thermal insulation layers, and protective coatings that prevent catastrophic failures before they occur. These features are integrated into the manufacturing process to provide inherent safety without complicating production.
Solution Approach 2:
The design converts potentially harmful factors into beneficial safety mechanisms. For example, pressure buildup from thermal runaway is channeled through controlled venting paths that release pressure safely, and conductive elements are designed to break circuit under excessive current rather than causing short-circuits.
3Power
If battery cells are designed for high power output, then vehicle acceleration improves, but individual cells become heavy and bulky
Solution Approach 1:
The battery cell design uses locally optimized materials and structures in different regions. The housing employs lightweight composites where weight reduction is critical, while maintaining thicker walls in areas requiring structural strength or thermal management. Electrode materials are selectively distributed to maximize power density in high-demand areas.
Solution Approach 2:
The battery cell incorporates composite materials including lightweight alloy housings, carbon-fiber reinforced components, and advanced electrode composites that provide high power output with reduced weight. The connector assembly uses composite construction combining conductive metals with lightweight insulating materials.
Data Source
Figure 1~2A
Figure 2B~2D
Figure 3~4
AI summary
An electrochemical storage cell (300) comprises a core and a rectangular shell (305) that receives the core (200) snugly therein. The rectangular shell (305) has first and second open ends. A first end cap (335) is used to close the first open end. An anode terminal extends through the first end cap (335) from an interior portion of the electrochemical storage cell (305) to an external portion thereof. A first gasket (1405) is secured within the rectangular shell (305) between the first end cap (335) and the core (200) to resiliently hold the core (200) away from the first end cap (335). A second end cap is used to close the second open end. A cathode terminal extends through the second end cap from an interior portion of the electrochemical storage cell to an external portion thereof. A second gasket is secured within the rectangular shell between the second end cap and the core to resiliently hold the core away from the second end cap.